Mineral wool manufacture



Nov. 13, 1945. E. R. POWELL MINERAL WOOL MANUFACTURE Filed April 29,1943 INVENTOR [bu 4m) A? an 44 ATTORNEY Patented Nov. 13, 1945 v MINERALWOOL momma Edward R. Powell, North Plainfleld', N. J.,-aasignor toJohns-Manville Corporation, New York,

N. Y., a corporation of New York Application April 29, 1943, Serial No.485,010

'1 Claims. (CI. 49-1) My present invention relates to the manufacture ofmineral wool and like products and more particularly to improved meansfor applying a binder to mineral wool fibers substantially at the timeof their formation. It will be understood that the term mineral wool" isemployed herein in a generic sense to include wool or fibers formed fromrock, slag. glass, mixtures thereof and other suitable raw materials.

Heretofore mineral wool has been manufactured in severa1 ways, forexample, by subjecting a stream of the molten material to the action ofa high pressure steam jet. More recently it has been proposed todisintegrate the molten material by the use of one or more spinners orrotors rotated at high speed and upon which the material impinges and bywhich it is broken up into drops or masses which are thrown'from therotor by centrifugal force and drawn into thread or fiber form. Theprincipal object of the instant invention is the provision of a. binderaddition means for use in conjunction with apparatus of the latter typeand which will provide a relatively uniform distribution of the binderin fine droplet form throughout the newly formed fibers.

Another object of the invention is the provision of such binder additionmeans which will deliver the binder throughout substantially the entirearea of fiberization.

Another object of the invention is the provision of an atomizing typebinder spray head adapted to form a cloud of minute droplets of binderadjacent the peripheries of the fiberizing rotors, and further toprovide a spray head of this type which may be adjusted to control thebinder concentration to provide a larger amount of binder adjacent theplaces of maximum fiber production.

A still further object of the invention in one form thereof is theprovision of means to be employed in conjunction with a binderapplicator of the type referred to above, to eliminate or substantiallyreduce whipping and eddying the cloud of binder droplets by the windageeflects produced by the rotor.

My invention will be more fully understood and further objects andadvantages thereof will become apparent when reference is made to themore detailed description thereof which is to follow and to theaccompanying drawing, in which:

Fig. 1 is a diagrammatic elevational view of a mineral wool apparatusillustrating the arrangement of the fiberization and binder applyingapparatus in accordance with the invention;

Fig. 2 is a view on an enlarged scale taken on the line 2-2 of Fig. 1;

Fig. 3 is a top plan view of the apparatus shown in Fig. '2;

Fig. 4 is an enlarged sectional view of the spray head shown in Fig. 2,the view being taken on the line 4-4 of Fig. 2;

Fig. 5 is a perspective view of an apparatus embodying a'further featureof the invention;

Fig. 6 is an elevational view of the apparatus of Fig. 5 with parts insection; and

Fig. '7 is a view similar to Fig. 4 illustrating a modified form of thespray head.

Referring now to the drawing and more particularly to Figs. 1-4inclusive, there is shown an apparatus for melting and fiberizingsuitable raw materials such as rock, slag, glass and mixtures thereof.The fiber forming elements of the apparatus may take different formsbut, as illustrated, the same comprise a melting furnace III of thecupola or tank furnace type and a fiberizing means indicated generallyat l2. Fiberizing means It includes one or more rotors. In-

the form illustrated, two. cylindrical rotors l4 and iii are employedhaving, respectively, cylindrical surfaces l5 and I1 and end surfaces l9and 2|, whose peripheries define the cylindrical surfaces. The rotorsare carried by shafts l8 and 20, respectively, and are adapted forrotation at high speed in opposite directions. The rotors are positionedso that rotor l 4 receives the stream of molten material on itscylindrical surface-the molten material being partially converted intofibers by rotor I4 and partially discharged onto the cylindrical surfaceof rotor it where further fiberization-takes place. Fiberizatlon iscaused,

fiberizing system is shown only for purposes of illustration and thatthe invention is not limited to the particular number of rotors to beemployed.

Behind the rotors there is provided means indicated generally at 22 fordelivering a binder in finely divided form to the fibers as, or shortlyafter, they are formed. The binder applying device includes a spray head24 for each rotor supported in any suitable manner behind the rotoradjacentone of its end surfaces and somewhat ofi center but preferablywithin the space defined by the extended cylindrical surface of therotor, as indi- -*cated. Each sprayhead 24 comprises a pair of of themarginal area of the-members and is located opposite the shaft of therotor where no binder spray is required. Member II is provided with aninternal channel 38 into which a binder supply line 38 is connected.Channel 38 terminates in a mouth 40 opening into the space between themembers and substantially at the center of the space. Where multiplerotors are employed, as shown in Figs. 1 to 3, the binder supply line 38for each ofthe spray heads may be Joined to a main binder supply line42, which in turn is connected to any suitable source of binder supply(not shown). v

Member 28 is provided with a perforation or opening opposite mouth Iiiinto which a pipe 44 is threaded or otherwise secured. Pipe 4 isconnected to a suitable supply of a. fluid medium u'nder pressure and,where multiple rotors are employed, may form branches of a main pressureline 48 leading from a high pressure steam line, compressed air line orthe like.

es behindrotor u, but it will be understood that it is equallyapplicable to rotor IL As will be Supply lines 38, ll, 42 and 48 mayserve as the' and 2B and escapes from said space at high velocitythrough the annular port 33. At the same time the binder material issupplied by lines 42 and 38, preferably under pressure, and entersthrough mouth into the space between the members 26 and 28. Entry of thebinder into the space will be aided by the aspirating action of thesteam or other fluid escaping through port 33. The binder is atomizedand driven through the orifice in the form of fine droplets or particlesby the escaping steam. Due to the fact that the binder is sprayed outthrough a substantially circular orifice it will be directed adjacentthe periphery of the end surface of the rotor. and will contact thenewly formed fibers throughout the entire flberizing area. Where it isfound that the fiber yield is higher at certain points than at others,as is usually the case, the amount of binder may be increased at thesepoints and correspondingly decreased at others by localized adjustmentof the width of the annular orifice. This may be accomplished in anysuitable manner. For example, as shown in Fig. "I, at least one of themembers or discs defining the orifice may be made of relatively lightweight material, whereby the orifice may be varied at desired locationsby forcing the edges of the members closer together or farther apart, asthe case requires.

Referring now to Figs. 5 and 6, a further feature of the invention isdisclosed for use in conjunction with the binder applying device androtors described above. This feature comprises a bailie 50 preferably ofsomewhat conical shape located behind the rotor and between it and thebinder applying device and supported as by bracket 52 secured to anysuitable fixed portion of the apparatus. A baffle has been shownmountunderstood, rotors of the type of I4 and It, when driven' at thehigh speeds employed. say, 8800 to 4600 R. P. M., create a windage whichtends to whip the cloud of binder particles and set up eddy currentstherein which interfere to a considerable extent with the properdistribution of the binder. Also a portion of the binder is whipped intocontact with the rotor where it has an undesirable cooling effect. Inthe case of certain types of binders, contact with the rotors causesrapid burning or flashing of the binder. If a heat-setting binder isemployed it tends to be set up by contact with the rotors and to buildup thereon to an undesirable extent. 7

These various difficulties are avoided by no! fie ill which does notattain a temperature comparable with that of the rotor, as it is notcontested by the molten material and hence has no harmful effect on thebinder. Also the bailie plrevents interference with the binder distribu-The apparatus of the instant invention may be employed with any suitablebinding material. For example, heat-setting binders such as Bakeliteresins, drying oils and the like have been found to be suitable.Thermoplastic binders such as thermoplastic resins, asphalts, waxes andthe like may also be employed.

Having thus described my invention in rather full detail, it will beunderstood that these-details need not be strictly adhered to, but thatvarious changes and modifications will suggest themselves to one skilledin the art, all falling within the scope of the invention as defined bythe subioined claims.

What I claim is:

1. In a mineral wool apparatus, means for disand and surfaces havingperipheries defining said cylindrical surface, and means for applying abinder to said fibers, said last-named means comprising a spray headsupported adjacent one end surface of the rotor and having asubstantially continuous annular port positioned for directing a binderspray adjacent the periphery of said one end surface.

2. In a mineral wool apparatus, means for disintegrating a stream ofmolten material into fibers, said means comprising a rotor having acylindrical surface on which said stream impinges and end surfaceshaving peripheries defining said cylindrical surface, and means forapplying a binder to said fibers, said last-named means comprising asprayhead adjacent one end surface of the rotor and within the spacedefined by the extended cylindrical surface of the rotor and having asubstantially continuous annular port for directing a binder sprayadjacent the periphery of said one end surface.

3. In a mineral wool apparatus, means for disintegrating a stream ofmolten material into nbers, said means comprising a rotor having acylindrical surface on which said stream impinges and end surfaceshaving peripheries defining said cylindrical surface, and means forapplying a binder to said fibers, said last-named means comprisingmembers having spaced, substantially fiat siu'faces defining an annularport within the space defined by the extended cylindrical surface of therotor, means for supplying a binder matcrlal to the space between saidflat surfaces and means for supplying fluid under pressure to saidlast-named space whereby said fluid escaping through said port draws thebinder therewith and sprays the binder onto said fibers.

4. In a mineral wool apparatus, means for disintegrating a stream ofmolten material into fibers, said means comprising a rotor having acylindrical surface on which said stream impinges and end surfaceshaving peripheries defining said cylindrical surface, and means forapplying a binder to said fibers, said last-named means comprising apair of circular plates, each having a cylindrical surface and asubstantially flat end face with said end faces of said plates inadjacent relationship to define a circular port, a passageway within oneof said plates extending from the cylindrical surface thereof to a mouthsubstantially centrally of its said end face, means connecting saidpassageway to a binder supply, a passageway in the other of said platesterminating in a mouth in its said end face substantially opposite tosaid mouth in the first-mentioned plate, and means for supplying a fluidunder pressure to said passageway in said second-mentioned plate.

5. In a mineral wool apparatus, means for disintegrating a stream ofmolten material into fibers, said means comprising a pair of rotors insubstantial tangential relationship, each having a cylindrical surfaceand end surfaces including peripheries defining said cylindricalsurface, and means for applying a binder to said fibers adjacent theperiphery of an end surface of each of said rotors, said last-namedmeans comprising spray heads supported adJacent one end surface of eachrotor and within the space-defined by the extended cylindrical surfacethereof and having a substantially continuous annular port, and a bindersupply line and a supply line for a fluid under pressure connected intoeach of said spray heads.

6. In a mineral wool apparatus, means for disintegrating a stream ofmolten material into fibers, said means comprising a rotor having acylindrical surface on which said stream impinges and end surfaceshaving peripheries defining said cylindrical surface, a fixed baflleplate overlying one end surface of the rotor and substantiallyco-extensive therewith, and means for applying a binder to the fiberssubstantially as they are formed by said rotor, said last-named meanscomprising a spray head supported adjacent said baffie plate and withinthe space defined by the extended cylindrical surface of the rotor andhaving a substantially continuous annular port.

7. In a mineral wool apparatus, means for disintegrating a stream ofmolten material into fibers, said means comprising a rotor having acylindrical surface on which said stream impinges and end surfaceshaving peripheries defining said cylindrical surface, a conical baiileplate, means for supporting said baifle plate adjacent one end surfaceof the rotor, said baffle plate being substantially co-extensivetherewith, and means for applying a binder to the fibers substantiallyas they are formed by said rotor, said last-named means comprising aspray head supported adjacent said baifle plate and within the spacedefined by the extended cylindrical surface of the rotor and having asubstantially continuous annular port, and a binder supp y line and asupply line for a fluid under pressure connected to said spray head.

EDWARD R. POWELL.

